Repair

This engine is equipped with dual spring injectors. Injection therefore occurs in 2 stages.
These injectors must be replaced if malfunctions occur because neither servicing nor pressure adjustment is possible.

WARNING:
- Fire hazard! Do NOT have anything in the area that can ignite Diesel fuel.
- When testing injectors, ensure that the stream of fuel does not contact the hands. The fuel (which is under high pressure) can penetrate the skin which could lead to severe injuries or health complications.

Special Tools, Testers And Auxiliary Items:
- VAG 1322 Fuel injector test stand

Test Conditions:
- Pressure gauge installed

Injection Pressure, Checking:





- Connect fuel injector to injector test stand
- Move pump lever down slowly
- Read off opening pressure when spray begins
Specification (new injectors): 190 to 200 bar.
Wear limit: 170 bar.

If reading deviates from specification:
- Replace that fuel injector

Leak Checking:
- Pressure gauge ON
- Move pump lever down slowly and maintain a pressure of approx. 150 bar for 10 seconds
No fuel should leak from the nozzle tip
- Replace any leaking injectors